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Direct coating
Innovation in Motion Company Speaker Miba Coating Group Eitzinger Günter Chief Engineer No powertrain without Miba Technology Divisions at a Glance Miba 5000 Employees worldwide Bearing Group Sinter Group Friction Group Innovation in Motion New Technologie Coating s Group Group Innovation in Motion Direct coating of conrods and bushings substitution of sliding bearings MIBA Coating Group Friction losses example Daimler Source: Motorsymposium 2012 Vienna Innovation in Motion Bearingless Conrod – Direct coating • Increased load ability • Smaller bearings • Less hydrodynamic friction • Smaller tolerances • Reduced Weight • Increased stiffness • Smaller engine • Less oil consumption • Smaller oil pump Innovation in Motion Example picture Innovation in Motion Basic Technology Miba Invention: The Cylindrical Cathode Advantage: Uniform Layer also for thick layers and large bearings eAr+ Sputtering Process: eee- Cathode (ca. 600V) ee- 1. Argon Ions Bombard the Cathode 2. Al and Sn Atoms are released by the kinetic energy of the Ions 3. Freed Atoms are moving through the cylindrical space and form the layer of the bearing Innovation in Motion Concept and Machinery Sputtering Coating 1 Ni Sputtering Coating 2 Loading Ion Etching Cleaning View into Coating Chamber Star Concept: Diameter: 30 – 190 Batch Concept: 190mm to 350 mm Miba Sputter Bearing AlSnX Innovation in Motion 4 Description: AlSn20 layer applied using a Miba-developed PVD sputtering process 4 Application: High performance engines with high power density for high speed ferries, locomotives, ships and automotive applications 4 Characteristics: Extraordinary high load carrying capability, good tribological properties and superior wear resistance Roll bonded AlSn Sputtered AlSn Innovation in Motion Hydro-dynamic Bearing Type Performance Kleinster Schmierspalt [µm] min oilfilm thickness [µm] 0.8 0.9 1 Bauarten / Bearing T ypes Prototype Standard Development Application Area Sputter . Application Area Tri-Metal . Sputter NEW Sputter Bearing Synthetic OL PnSnCu PRO Rillenlager SnSb PRO 2 3 Outstanding Hydrodynamic Performance Tri-Metal Bearing BIAL AlSn25 AlSn20 BIAL AlSn20 4 AlSn40 5 1000 1500 Application Area Bi-Metal 2000 2500 3000 3500 4000 . 4500 Schmierfilmspitzendruck [bar] max Oilfilm Pressure [bar] 5000 5500 Sputter Coating Properties Innovation in Motion New Al- based Alloy: • Sn content ~20 wt. % • Al - Matrix Alloy Composition: Sputter - Layer Ni - Layer Sn 20 % Bronze Cu 2 % Al 78 % References: Cross Section: Hardness: 80 - 120 HV Passenger Car: All European Common Rail Diesel Engines Heavy Duty Truck: DC, MAN, DAF … High Speed: mtu, MWM - Deutz, CAT … Medium Speed, GAS: GE - Jenbacher … Improved Sputtered Overlay Properties Innovation in Motion New Al- based Alloy: • Sn content ~25 wt. % • Near eutectic AlSi- matrix New Alloy Composition: Sputter - Layer Ni - Layer Al 67,5% Bronze Si 7,5% Sn 25,0% Cross Section: Production parameters: Ø Similar to AlSn20Cu Grain size: Sn < 1 µm Si << Sn Hardness: 130 - 150 HV Innovation in Motion Relative Bearing Type Performance Best Overall Performance of all known Bearing Types Best Overall Performance in High Loaded Applications with Dirt Shock and Dirt Contamination Film Thickness Fatigue 80 Bearing Types Sputter AlSnSi Sputter Std. Tri-Metal 60 Emergency 40 Test Results after 15 hours running time Dirt Contamination Test - - 100% Oil - Test runs without oilfilter 20 0 20 40 60 80 Cl - Corrosion 100 80 Dirt volume 60 Survival Rate [%] 40 Wear 20 S - Corrosion Cavitation 0 Trimetal Bearing 22 µm Overlay Trimetal Bearing 3 µm Overlay Rillenlager Sputtered Bearing 14 µm Overlay Bearingless Conrod – Direct coating 1. Layer 2. Layer Innovation in Motion 20 - 60 µm AlSn20Cu 5 - 20 µm Synthec®Pro - Sliding Lacquer Bearingless Conrod – Direct coating Innovation in Motion „Lemmon shape“ Compensate deformations Caused from masses of inertia Taylor made Sputter Machines Capacity and Capability: • Diameter Range 30 to 350 mm • AlSn20, AlSn25 Si • More than 50 Million coated bearings Innovation in Motion Sliding lacquers: Synthec™Pro Innovation in Motion Engine : EA 888 Audi 4 Cylinder Gasoline (World engine) Integrated Mass Balancer System Engine Start Stop – reduced friction , improved emergency behavior of the system Rotational speed : max. 14000 rpm Max. Torque: max. 60 Nm One Radial- and two integrated axial bearings on a net shape sintered part Detail Synthec®Pro on Sintermaterial Innovation in Motion Typical structure of a 20 µm Synthec®Pro overlay on a powdermetal part Test arrangement Ring on disc tests SynthecPro® (oil jar not shown) • 100Cr6 Ring • 1.2379 disc Ø40mm 58+2HRC coated, submerged in Shell Helix Ultra 5W30 • Specific load 1-3-5MPa • Temperature: 55°C Innovation in Motion Innovation in Motion COF versus Load of Synthec Pro ® 100Cr6 ring against SynthecPro on 1.2379 hardened under Shell Helix Ultra 5W30@55°C cycles [1] 0 200.000 400.000 600.000 800.000 1.000.000 1.200.000 1.400.000 1.600.000 0,2 6 0,18 friction coefficient 0,14 4 0,12 0,1 3 0,08 2 0,06 0,04 1 0,02 0 0 10000 20000 30000 40000 50000 sliding distance [m] 60000 70000 80000 0 90000 specific load 5 0,16 friction coefficient [-] specific load [MPa] Synthec®Pro on AlSi9Cu3 Alloy Innovation in Motion Cross-section from a 21 µm SynthecPro Layer on an aluminium alloy. Nearly all materials Possible. Application examples of Synthec Pro Innovation in Motion sliding bearings split gears piston skirt sprockets bearing block intermediate gears Synthec Pro Properties Innovation in Motion Performance Attributes • • • • • • • • • Temperature range in applications (-50 up to 250°C) Superior wear behavior COF 0,03 – 0,08 (mixed friction area) Special adaptive behavior during running in time Due too solid lubricants extremely good emergency behavior Corrosion resistance Environmental friendly Potential for weight reduction Potential for cost reduction Direct coating – Substitution of bearings Innovation in Motion Advantages: • Reduced weight • Reduced space • Smaller overall dimensions • Smaller width or diameter • Increased loadability • Degreased friction losses also in hydrodynamic condition • Enabler for use of low viscosity fluids >low friction • Less tolerances • Less assembly efforts Contact Miba Coating Group Günter Eitzinger Head of Advanced Engineering Dr. Mitterbauer-Str. 3 A-4655 Vorchdorf, Austria T +43/7614/6541-8200 F+43/7614/6541-8400 M +43/664/8560418 www.miba.com [email protected] Innovation in Motion
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